Metal pattern and method of making same



2 Sheets-Sheet 1 gwuemtop jr/ Uri ima e A. K. LAUKEL Fild Dec. 13, 1926iii A METAL PATTERN AND METHOD OF MAKING SAME Jan. 28, 1930.

Jan. 28, 1930. A. K. LAUKEL mam. PATTERN AND mswuov OF rumme sms FiledDec. 13. 1926- 2 Sheets-Sheet 2 Patented Jan. 28, 1930 I UNITED STATESOFFICE a ARTHUR KL LAUREL, OFDETROIT, MICHIGAN V i i METAL IPATTE-RhlAND METHOD OF MIAKING "SAME application filed December 13, 1926.SeriaI'No'. 154,530

fillet to become loose or separate from its support.

V This invention relates to the manufacture of mounted metal patterns:such as cope and drag plates, wherein such patterns are utilized forproviding the required impressions in the cope and drag of a mold,castings made in a parted mold in this manner being usuallycharacterized by the fact that they show the parting and it is oftenrequired that the mark ol the part be removed from the casting and thatthis be done in a neat, accurate manner without cutting into the body ofthe casting itself. In order tolacilitate the grinding or machining ofthe parting impression from the casting, it is 'c'ommonipr-actice toaccentuate the parting by providing'fillets on the pattern which Willcause a decided ridge of metal to 'be formed on the casting at theparting of the mold, which ridge is afterwards removed a suit-ablemanner as is well known in this art, and does not require furtherdescription hereinafter. I

The'use of such fillets is however attended with certain disadvantagesbecause ordinarily the pattern is not integral withthe plate on which itis mounted, mainly due to the fact that it must necessarily be separatefrom the plate during machining and finishing to give it the propersurface and contour and the plate ifintegral therewith would-interfereaowith such operations and rendert-hem very expensive it they were to beconducted by hand or by such processes as the limiting effect-of theattached plate would necessitate.

Therefore, it h'as been common practice to first completely machine orfinish the pattern and then secureit to the cope'or drag plate "as thecase may loe, alter which a filletsuch' usually necessary to giveititheproper con tour and bind the edges of it smoothly into the surface oft-heipattern and the plate, and

also is often difficult to secure a proper adhesion of the solderthroughout the length of the fillet to both the pattern and the plate 56th emst mes ther sisat n sney a t By my present invention I proposetoovercome all these disadvantages and provide a pattern plate andfillet of an integral nature and secure this structure by electr'odeposition' in a cheap, simple and highly elleetive manner. I

I have described a somewhat'similar process to that disclosed herein, inmy co-pen'din we application, Serial No.- 101,069, filed Apri 10, 1926,wherein the making of core boxes is described, the dilierence inthis case being found in the provision of a filleted split patternespecially devised to overcome the par '5 ticular disadvantagesattending the ordinary methods hitherto employed 'inthe making offilleted sp-l-it patterns.

In carrying my invention into efiect I may adopt novel methodshereinafter described and "ascertained hereinafter by way of example,havingreterence to the accompanying drawings, 'wherei n I Figure 1 is aplan of a mold adapted to the making of a filleted split pattern byelectrodeposition in accordance with this invention;

Figure 2 is a section of the same on thelin'e Q -Q Figure 1; I

Figure 3 is a similar view to Figure 1, illustrating metal insertsapplied to the mold 9 for giving strength and rigidity to the plate 7 ofthe pattern to be formed;

Figure 4 is a sectional view taken'on the line P- l", Figure 3; I

Figure 5 is'xa' similar viewto Figure 3,=il "s5 lustra ting theappearance of the mold after metal has been electrolytically depositedtherein; I

Figure =6 is :a section-on the line 6 Fi-gure5; I WQYO Figure .7 is abroken perspective view of :a working master pattern used making themold, Figure 1; Q; F gure "-7 is a similarview of :a completedelectr0=deposited isplit pattern removed from '95 the mold;-and I r 1Figure 8 is a perspective view of a 'casting made by means of thepattern illustrated in Figure 7. o 7 Similar, charactersxof referenceindicate similar parts in the several figures of the drawings.

The mold for making the electro-deposited pattern may be of any suitablematerial which will lend itself to the carrying out of the operationsherein described, and I have used in a quite satisfactory manner forthis purpose, plaster of Paris, suitably treated as with wax to renderit acid resistant to an extent enabling it to withstand the action ofacid in the electrolyte in which the electro-deposition of the patternis effected.

In Figure 7 is shown a master pattern which may be of wood, metal orother material having a plate 1 upon which is mounted the pattern body2, these parts usually being separately made for convenience inmachining and finishing and afterwards secured together, after which afillet 3 is provided about the edges of the pattern to eliminate thesharp angles or corners which would otherwise exist at such points, andwhich are to he usually avoided for reasons well known in the metalmolding art. Some of these reasons have already been referred to, andstill further, it might be mentioned that the existence of sharp edgesin a mold at the parting is also objectionable as tending to offer anobstruction to the flow of metal over such edges, this sometimesresulting in the breaking down of the said edges and consequentformation of the undesirable deformities in the casting.

The fillets 3 of the master pattern in the case of a wood pattern may beof wax or leather, and in the case of a metal pattern, of solder or anyother suitable material, and are in many cases diflicult to provide in aneat and efiicient form or to insure their remaining in place and intactthroughout long use.

In making my improved pattern by the improved method, I take a masterpattern such as that referred to and make a plastic cast about suchpattern so that the plastic cast will have formed therein the impressionof both the plate and the pattern proper as well as the fillet, Figure 1illustrating such a plastic cast 4, wherein 5 is the impression of theplate 1, 6 the impression of the pattern body 2, and 7 the impression ofthe fillet. Of course, the master pattern used for the making of theplastic cast may be simply a pattern which has already been constructedby the processes described herein and may be of an electrodepositednature with the plate, fillet and pattern proper in one piece, and arenot necessarily always made from a specially constructed master patternas will be readily understood. In other words, a pattern having beenmade by the herein described process, it may be reproduced in any numberwithout having recourse to the original master pattern.

The mold of plastic composition, Figure 1, having been made, the surfaceof the mold on which the plating is to be deposited, that is,

the surface of the cavities 6 and surrounding parts of the mold uponwhich metal is to be electrolytically deposited, is suitably coated orprovided with a film or surface of conducting material, such for exampleas silver sulphide which is indicated in Figure 2 by the heavy line 8.The margins of such coating are indicated by the lines 8 in Figure 1,although such coating may extend throughout the entire surface of theplate impression 5 if so desired, but in the present case that is notnecessary due to the fact that brass or similar inserts 9 are indicated,see Figures 3 and 4, as being utilized in connection with the formationof the plate of the pattern to be produced. These inserts are notabsolutely essential, and are simply used for the purposes of reducingthe area to be plates, of giving rigidity to the plate of the pattern tobe formed which, would not be secured to an equal extent were the entireplate of electrolytically deposited metal, and to provide substantialanchoring means whereby the plate may be secured to any suitable supportor backing.

Where the pattern is to be utilized in a jolt molding machine, andsubjected to the vibration and strains occurring in connection with suchmachine molding, strength in the plate of the pattern, is moreparticularly desirable, and it is for that reason that the use of suchinserts of strong metal such as brass is suggested.

These inserts 9 terminate at some little distance from the margins ofthe mold cavities 6, and the edges of the inserts presented towards themold cavities are preferably beveled as at 10 so that a substantiallyobtuse angle is formed between the surface of the plastic mold and themargins of the metallic inserts, thus avoiding sharp angles in which itis diflicult to secure adequate metal deposit.

The metallic inserts overlap the margins 8 of the conductive surface ofthe plastic mold, and they may be secured in position by screws 11. Themold is then plated in a suitable plating bath such as a copper sulphateelectrolyte, cathode connection being made to the conducting surface ofthe mold as through the medium of one of the screws 11, and the methodemployed in effecting the plating may be similar to that described in myco-pending application, Serial No. 101,070, filed April 10, 1926, anddoes not call for detailed explanation herein, except to say that thedeposition is effected over the surface of the cavities and of the plateimpression of the mold to the inserts, where such are provided, so thatthe said inserts become an integral part of the deposited pattern andmore particularly a 1 5 part of the plate of the pattern. Paper or otherinsulation 9 may be applied over the inserts 9 to prevent unnecessarydeposition of metal on the faces thereof.

Figures 5 and 6 clearly indicate the result inserts left vacant by theremoval of screws 11 being suitably filled with metal if so desired, thesaid metallic device then having the appearance shown in Figure 7 a ofthe drawing, in which 12 is the pattern body, and 13 the plate of thepattern integral therewith and with the fillet 14 which forms anintegral merging of the said pattern body into the plate of the pattern,as will be readily understood.

In making castings by means of the pattern shown in Figure 7 the patternbody is impressed in both the cope and drag portions of themold in amanner well known in the art, the mold being suitably cored and theresulting casting has the appearance shown in Figure 8, wherein theparting line is characterized by a ridge 16 resulting from the presenceof the fillet 14 of the pattern, this ridge being so accentuated that itmay be easily removed without the danger of mutilating the body of thecasting which is present when provision for such ridges in the castingis not properly made.

It will be understood that the cope and drag patterns are not alwayssimilar as in the illustrated case and the margins of the cope and dragcavities are therefore not always coincident. Sometimes for instance thecope or drag portion of the pattern is plain without any impression, andin this case the fillet of the pattern serves to provide a rib or flangeabout the margins of the casting which may be easily removed andovercomes the tendency of molten metal to avoid completely fi ling thecorner or. angle between the margins of the moldcavity and the opposedsurface of the other half of the mold, or to shrink away from suchcorners or angles.

'The'pattern, Figure 7 in actual use is similar to that shown in Figure7, but its capacity to withstandihard usage, its simplicity ofmanufacture "and reproduction, and

its unbroken contourbetween plate and pattern body present advantages"over a builtup pattern; as in Figure 7, provided with applied fillets,which, advantages have not hithertobeen available in the mountedpatterns made according to prior art methods and overcome theditficulties set forth in the. general statement of the nature of the invention. I v

This invention may be developed within the scope of the following claimswithout departing from the essential features of the said invention, andit is desired that the specification and drawing be read as merelypattern body on a plate, applying a fillet to said pattern, formlng in amold the impression of the plate, pattern body and fillet, and effectingthe electro-deposition of metal on the surface of said impression toprovide an electro-deposited reproduction of the plate, pattern body andfillet as an integral body.

2. The methodof making mounted metal patterns which comprises mounting asplit. pattern body on a plate, applying a fillet to said pattern,forming in a mold the impression of the plate, pattern body and fillet,effecting the electro-deposition of metal on the surface of saidimpression to provide an electro-deposited reproduction of the plate,pattern body and fillet as an integral body, and subsequently backingsaid reproduction with a suitable material to give strength thereto.

3. As a new article of manufacture, a

mounted metal pattern comprising a face plate and an electrolyticallydeposited pattern integral with said face plate, the junction of themargins of said pattern with said face plate being in the form of anelectrolytically deposited integral fillet.

4. A method of making mounted metal patterns which consists in formingthe impression of the plate, pattern body and fillets of a mountedpattern in a mold, laying metallic plate material in the plateimpression and at a distance outwardly from the pattern body and filletimpressions, and effect. ing the electro deposition of metal on saidlatter impressions, whereby said deposited metal adheres to said platematerial.

In testimony whereof I aflix my signature.

ARTHUR K. LAUKEL.

